Roof/wall structure

ABSTRACT

A roof/wall structure includes a substantially rigid substrate and a waterproof membrane adhesively joined to an outer surface of the substrate. The membrane includes a layer of thermoplastic or elastomeric waterproof material, a layer of cushion material bound to an inner surface of the layer of waterproof material, and a pressure sensitive adhesive bound to a side of the layer of cushion material remote from the layer of waterproof material and bound to the substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a division of application Ser. No. 11/983,995, filed Nov. 13,2007, which is a division of application Ser. No. 11/881,245, filed Jul.26, 2007, both in the names of Brian J. Whelan, Gary W. Whittemore, DanBen-Daat and Jon M. Jensen. This application claims priority from U.S.Provisional Patent Application No. 60/856,155, filed Nov. 2, 2006, andU.S. Provisional Application No. 60/934,785, filed Jun. 15, 2007, bothfiled in the names of Brian J. Whelan, Gary W. Whittemore, Dan Ben-Daat,and John M. Jensen.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is directed to a self-adhering membrane which may beapplied to roof and/or wall structures, particularly “green” roof andplaza deck constructions, including planters, balconies, terraces,foundation walls, tunnel structures, and the like.

2. Description of the Prior Art

It has become increasingly popular to provide new building and otherconstructions with green roofs, that is, roofs supporting earth, grass,and plantings, often with walk-ways and/or terraces. The roof decksfrequently are made of structural concrete or metal decking covered witha rigid hardboard, sometimes metal-covered, and covered with awater-proof thermoplastic membrane applied to the outside surface of theconcrete, rigid hardboard, or other substrate. Inasmuch as the membraneis typically of the type customarily used on conventional non-greenrooftops, and having a thickness of about 60 or more mils, the membranemust be applied to a very smooth and clean concrete, rigid hardboard, orother rigid surface. Irregularities in the smoothness of the outsidesurface of the substrate can produce perforations and punctures in themembrane which breach the water-tight integrity of the membrane. Thesame problem applies to foundation walls, tunnel structures, and thelike, of structural concrete or masonry.

In an effort to better absorb and conform to irregularities in thesubstrate surface, a layer of felt-like material has been used to form acushion layer of sorts between the substrate surface and the waterproofmembrane. However, it has been discovered that while perforations andpunctures in the membrane are reduced, any that remain or occurallow-water passing therethrough to flow into the felt-like materialwhich acts like a wick and spreads the water out in directions not easyto determine. Because of lateral migration of the water, a leak in themembrane in a first area may make itself known in remote second areas.Determining the location of the leak into the underlying structure canbe extremely difficult, expensive and time-consuming to accomplish,inasmuch as removal of the overburden is required to gain access to abreach in the membrane.

To overcome the above-noted problems, resort has been made to adheredliquid materials, such as hot rubberized asphalt (HRA), a system which,as the name implies, involves the laying down of HRA in the form of ahot liquid, usually of about 150-215 mils thickness. In such procedures,precautions must be taken with respect to workers inhaling fumes,handling hot kettles, and the hot asphalt. The odor and smell of asphalttends to travel and irritate nearby site workers, building occupants andgeneral public. Further, usually no portion of the area can be usedduring installation of HRA nor after installation until the HRA coolsand solidifies.

Cold-applied liquid products are also used in such applications, bestinstalled in thinner coatings of around 60 mils thickness. Suchmaterials have fewer application issues inasmuch as they are applied atambient temperatures, but often contain solvents which have odors andrepugnant smells, or, when spray-applied, produce air-borne particulatesthat create a potential hazard for installers, site workers, andbuilding occupants.

Thus, there is a need for an effective, efficient, less expensive, odorand solvent-free, and less hazardous material and method for laying awaterproofing membrane down over a structure that is subject to a wet ormoist external environment.

Accordingly, an object of the invention is to provide a waterproofingmembrane for application to a surface of a structure to providewaterproofing and moisture protection to the structure, and which doesnot provide a medium for lateral migration of water therethrough.

A further object of the invention is to provide a method for making awaterproof membrane for application to a surface of a structure.

A further object of the invention is to provide a roof/wall, foundationor tunnel structure providing watertight integrity.

A still further object of the invention is to provide a method forwaterproofing a roof and/or a wall, foundation or tunnel structure.

A still further object of the invention is to provide a method forincreasing puncture resistance of a thermoplastic or elastomericmembrane for use in water proofing subterranean structures and surfaces.

SUMMARY OF THE INVENTION

With the above and other objects in view, as will hereinafter appear, afeature of the present invention is the provision of a membrane forapplication to a surface of a structure to provide waterproofing andmoisture protection to the structure. The membrane includes an outersurface layer of thermoplastic material, a layer of cushion materiallaminated to, or fused to, or adhered to, an inner surface of the layerof thermoplastic material, a pressure sensitive adhesive bound to a sideof the cushion material remote from the thermoplastic layer, and arelease liner removably mounted on the remote side of the pressuresensitive adhesive.

In accordance with a further feature of the invention, there is provideda method for making a waterproof membrane, the method comprising thesteps of providing a layer of cushion material, bonding a layer ofwaterproof thermoplastic material to a first side of the layer ofcushion material, affixing a layer of pressure sensitive adhesive to asecond side of the layer of cushion material, and mounting a releaseliner on a side of the pressure sensitive adhesive remote from thecushion material.

In accordance with a further feature of the invention, there is provideda roof/wall, foundation or tunnel structure (hereinafter “roof/wall”)comprising a substantially rigid substrate, and a laminar membraneadhesively bonded to an outer surface of the substrate. The membranecomprises an outer surface layer of thermoplastic or elastomericwaterproof material, a layer of cushion material bound to an innersurface of the layer of the waterproof material, and a pressuresensitive adhesive bound to a side of the cushion material remote fromthe waterproof material layer, and bound to the substrate.

In accordance with a still further feature of the invention, there isprovided a method for waterproofing a structural surface. The methodcomprises the steps of providing a membrane for application to thesurface, the membrane comprising an outer surface layer of thermoplasticmaterial, a layer of cushion material laminated to, or fused to, oradhered to an inner surface of the layer of thermoplastic material, apressure sensitive adhesive bound to a surface of the cushion materialremote from the thermoplastic layer, and a release liner removablymounted on the remote side of the pressure sensitive adhesive, removingthe release liner to expose the pressure sensitive adhesive, andpressing the pressure sensitive adhesive against the structural surfaceto conform the layer of cushion material to the structural surface andbind the waterproofing membrane to the structural surface.

In accordance with a still further feature of the invention, there isprovided a method for increasing puncture resistance of a thermoplasticmembrane for use in water proofing of subterranean structuralsubstrates. The method comprises bonding a layer of cushion material tothe thermoplastic membrane, the cushion material comprising a cellularfoam material, the cushion material being adapted to conform aroundminor irregularities in a surface of the structural substrate.

The above and other features of the invention, including various noveldetails of construction, combinations of parts, and method steps, willnow be more particularly described with reference to the accompanyingdrawings and pointed out in the claims. It will be understood that theparticular laminar combinations and methods embodying the invention areshown by way of illustration only and not as limitations of theinvention. The principles and features of this invention may be employedin various and numerous embodiments without departing from the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is made to the accompanying drawings in which are shownillustrative embodiments of the invention, from which its novel featuresand advantages will be apparent.

In the drawings:

FIG. 1 is a diagrammatic sectional view of one form of a portion of awaterproofing membrane illustrative of an embodiment of the invention;and

FIG. 2 is a diagrammatic sectional view of one form of a portion of awaterproofed roof/wall structure illustrative of a further embodiment ofthe invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, it will be seen that the illustrative waterproofingmembrane 10 includes an outer surface layer 12 of thermoplasticwaterproof material, such as vinyl or polyolefin, bonded to a cellularfoam backing layer 14 coated with a pressure sensitive adhesive 16. Thebonding of the backing layer 14 to the surface layer 12 may beaccomplished by adhesive adhering, laminating, extrusion coating, heatsealing, gluing or taping, or the like. A manually removable releaseliner 18 is mounted on an undersurface 17 of the pressure sensitiveadhesive 16 prior to application of the membrane 10 to a roof/wallstructure 20 (FIG. 2).

The total composite membrane 10 may be about 120-140 mils or greater, inthickness, including the layer of waterproof material 12, which may beabout 60 mils, or greater, in thickness, and the foam backing layer 14,which may be also about 60 mils, or greater, in thickness.Alternatively, the layer 12 may be 0.015-0.080 inch in thickness, andthe backing layer 14 may be 0.015-0.375 inch in thickness, dependingupon the particulars of a specific application or project.

The flexible foam backing 14 conforms around minor irregularities in theroof/wall structure 20. The pressure sensitive adhesive 16 provides astrong bond between the membrane 10 and the roof/wall structure 20, evenin the presence of water and concrete alkalis.

The structure 20 typically is a green roof and/or a plaza deck servingas a roof structure for a work space or habitat therebeneath. Because ofthe heavy loads associated with such applications, the supporting deck20 is most often structural concrete. The external environment for suchroofs is generally at least damp and often subject to wetness, includingpooling or ponding. The structure may also be a foundation wall or anearth sheltered structure or tunnel. The membrane 10 accordingly isdesigned to protect the structure 20 from the effects of waterinfiltration which can lead to structural deterioration and interiorwater damage.

In one embodiment, the outer surface layer 12 is a thermoplasticflexible sheet, made of vinyl or polyolefin, most commonly with anintegral reinforcing material, such as glass fiber, polyester, nylon, orsimilar material. The backing layer 14 preferably is a cellular foam,such as a non-absorptive closed cell foam. The backing layer 14 isprovided with the pressure sensitive adhesive 16 which isfactory-applied and protected by the release liner 18 which is removedduring application. The laminar membrane 10 has been found tosubstantially increase puncture resistance, compared to standard priorart membranes which do not include a backing layer.

Preferably, the surface layer 12 extends beyond a side edge 22 of thefoam backing layer by about 2-4 inches to provide a selvedge 24. Themembrane 10 is shown in width-wise cross section in FIGS. 1 and 2 and istypically provided in rolls which are 6.5-12.0 feet in width with,additionally, the 2-4 inch selvedge 24 on one side. In positioning themembrane 10 on the structure 20, the membrane sheets are disposedside-by-side with the foam backing layers 14 tightly abutting eachother, and with the selvedge 24 overlapping the top of an adjoiningmembrane. The selvedge 24 is bonded, as by adhesives, glues, tapes,hot-air or solvent welding, to the overlapped membrane surface layer toprovide bonded seams which will not deteriorate in the presence ofwater, moisture, roots, micro-organisms, and the like.

There is thus provided a waterproofing membrane which can be applieddirectly to concrete and other substances. The membrane finds particularapplication to green roof, plaza deck, planter, balcony and terracesubstrates, foundation walls and tunnels, and is highly resistant tosub-grade environments of constant dampness, high alkalinity, exposureto plant roots, fungi, and bacterial organisms, as well as hydrostaticpressure, including ponded water conditions.

The membrane 10 is factory produced in its entirety. There is noassembly of the membrane at the work site; even the adhesive 16 by whichthe membrane 10 is applied to the structural substrate 20, is providedon the membrane and protected until the point of attachment by a readilyremovable release liner 18.

The membrane is made by providing the cellular foam backing, or cushionlayer 14, of a selected length and width suitable for subsequentpackaging in roll form. The layer of thermoplastic waterproof material12 is bonded to a first side of the cushion layer 14. The layer ofpressure sensitive adhesive 16 is deposited on a second side of thecushion layer 14, and the release liner 18 is mounted on the pressuresensitive adhesive 16 to completely cover the adhesive.

Preferably, the layer of thermoplastic waterproof material 12 extendsbeyond one side edge 22 of the cushion layer 14 to provide theaforementioned selvedge 24.

In the event of any incompatibility between the cushion material 14 andthe pressure sensitive adhesive 16, a barrier film 26 may be interposedtherebetween.

The assembled membrane components are then wound into roll form suitablefor placing on a substrate and un-rolled on the substrate, whilemanually removing the release liner 18 to place the membrane 10,adhesive side down, on the surface of the substrate 20.

Upon application of the membrane 10 to the substrate 20, there isprovided a roof/wall structure 30 (FIG. 2) including the substantiallyrigid substrate 20 and the waterproof membrane 10 adhesively bonded toan outer surface of the substrate, the membrane including the surfacelayer 12 of thermoplastic waterproof material, the layer 14 of cushionmaterial bound to the surface layer 12, and the pressure sensitiveadhesive 16 bound to a side of the cushion material 14 remote from thelayer of thermoplastic waterproof material 12, and bound to thesubstrate 20.

The waterproof membrane surface layer 12 is in the form of an elongatedstrip which extends sideways outwardly from the side edge 22 of thelayer 14 of cushion material to form the selvedge 24 (FIG. 1). Theroof/wall structure includes a plurality of the strips of membrane 10disposed on the substrate 20 lengthwise side-by-side with side edges 22of their respective cushion portions 14 abutting each other, and theselvedge 24 of one elongated strip overlapping, and heat welded orotherwise adhered to, the surface layer 12 of another elongated strip oflike structure.

The roof/wall structure thus formed is highly resistant to theaforementioned sub-grade environments.

There is further provided a method for waterproofing a structuralsurface. The method includes providing the waterproof membrane 10 forapplication to the surface, the membrane comprising the outer surfacelayer 12 of thermoplastic material, the layer of cushion material 14bound to an inner surface of the layer of thermoplastic material, thepressure sensitive adhesive 16 bound to a side of the cushion material14 remote from the surface layer 12 of thermoplastic material, and therelease liner 18 removably mounted on the pressure sensitive adhesive16.

The method includes the steps of removing the release liner 18 to exposethe pressure sensitive adhesive 16, and pressing the pressure sensitiveadhesive 16 against the structural surface to conform the layer ofcushion material 14 to the structural surface 20 and bind thewaterproofing membrane 10 to the structural surface.

The method for waterproofing the structural surface further comprisesproviding the layer 12 of thermoplastic material with a selvedge 24comprising an extension of the outer layer of waterproof material 12beyond a side edge 22 of the cellular foam cushion 14, preferably byabout 2-4 inches. The selvedge 24 overlaps a neighboring strip ofmembrane, while the cushion portion 14 of the two strips are in abuttingrelationship. The selvedge is bound to the neighboring waterproofsurface layer, as by heat-welding, adhesively, and the like.

Finally, there is provided a method for increasing puncture resistanceof a thermoplastic membrane 10 for use in water proofing of structuralsubstrates 20, the method comprising bonding a layer of cushion material14 to the thermoplastic membrane 10, the cushion material 14 comprisinga cellular foam material, the cushion material being adapted to conformaround minor irregularities in a surface of the structural substrate 20.

There is thus provided a membrane for application to a surface of astructure to provide waterproof protection to the structure, a methodfor making such a membrane, a roof/wall structure including themembrane, a method for waterproofing a structured surface using theaforementioned membrane, and a method for providing increased punctureresistance to a thermoplastic membrane.

It will be understood that many additional changes in the details,materials, steps and arrangement of parts, which have been hereindescribed and illustrated in order to explain the nature of theinvention, may be made by those skilled in the art within the principlesand scope of the invention as expressed in the appended claims.

For example, while the laminar structure described above is said toinclude a waterproof thermoplastic layer, and while such is regarded asa preferred embodiment, it will be apparent to those skilled in the artthat a waterproof elastomeric material could also serve as a waterprooflayer.

1. A method for waterproofing a structural surface, the methodcomprising the steps of: providing a waterproof membrane for applicationto the surface, the membrane comprising an outer surface layer of aselected one of thermoplastic and elastomeric material, a layer ofcushion material bonded to an inner surface of the layer ofthermoplastic or elastomeric material, a pressure sensitive adhesivebound to a side of the cushion material remote from the layer ofthermoplastic or elastomeric material, and a release liner removablymounted on the pressure sensitive adhesive; removing the release linerto expose the pressure sensitive adhesive; and pressing the pressuresensitive adhesive against the structural surface to conform the layerof cushion material to the structural surface and bind the waterproofingmembrane to the structural surface.
 2. The method in accordance withclaim 1, wherein the layer of thermoplastic or elastomeric material isprovided with a selvedge structure, and the selvedge structure is placedso as to overlap an adjacent outer surface layer of thermoplastic orelastomeric material, and is bonded to the adjacent outer surface layerto effect sealing of the membrane to an adjoining membrane of similarconstruction.
 3. The method in accordance with claim 1, wherein theouter surface layer of material comprises at least in part a selectedone of vinyl and polyolefin.
 4. The method in accordance with claim 1,wherein the outer surface layer is heat sealed to the layer of cushionmaterial.
 5. The method in accordance with claim 3, wherein the outersurface layer of thermoplastic material further comprises reinforcingcomprising one of glass fiber and polyester.
 6. The method in accordancewith claim 1, wherein the cushion material comprises a cellular foammaterial.
 7. The method in accordance with claim 6, wherein the cushionmaterial comprises a non-absorptive closed cell foam material.